WO2013124001A1 - Composé auto-stabilisant de matrice de métal d'aluminium et d'halloysite - Google Patents
Composé auto-stabilisant de matrice de métal d'aluminium et d'halloysite Download PDFInfo
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- WO2013124001A1 WO2013124001A1 PCT/EP2012/053226 EP2012053226W WO2013124001A1 WO 2013124001 A1 WO2013124001 A1 WO 2013124001A1 EP 2012053226 W EP2012053226 W EP 2012053226W WO 2013124001 A1 WO2013124001 A1 WO 2013124001A1
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- aluminum
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- hnts
- hnt
- halloysite
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/08—Making alloys containing metallic or non-metallic fibres or filaments by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K7/00—Use of ingredients characterised by shape
- C08K7/02—Fibres or whiskers
- C08K7/04—Fibres or whiskers inorganic
- C08K7/06—Elements
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/14—Making alloys containing metallic or non-metallic fibres or filaments by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
- C22C49/04—Light metals
- C22C49/06—Aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/14—Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
Definitions
- the present invention relates to a method for creating a reinforcing halloysite fiber network in an aluminum matrix resulting in a high strength metal matrix compound with improved ductility, elastic and fatigue properties.
- the compound material can be used for manufacturing low weight mechanical components requiring excellent ductility, elastic and/or fatigue properties, for instance, in aerospace, automotive, mass transportation, and construction applications.
- the present invention also relates to a method of manufacturing such an aluminum / halloysite compound material.
- fiber-reinforced materials with improved materials strength characteristics is an option to reduce weight of mechanical parts in aerospace, automotive, building, construction, and energy generating applications.
- metal-based-reinforced composite materials have increased in importance. Reinforcing metal materials with fibers makes it possible to clearly increase the mechanical strength characteristics and also, to some extend, the damage tolerance characteristics of metal materials. However, usually, those metal-based-reinforced composite materials show poor ductility, creep and fatigue characteristics and are significantly higher in cost. This is mainly due to increased production costs.
- a fiber-reinforced material is the lamination of metal sheets with fibers containing adhesive foils.
- a laminate which consists of at least two metal sheets, wherein a glass filaments containing plastic layer is disposed between the sheets.
- Such metal laminates are in particular suitable for lightweight structures for aircraft-related applications because these structures have advantageous mechanical characteristics while being of low structural weight.
- an alloy laminate material is known, wherein a plastic matrix, containing reinforcing fibers like carbon fibers, polyaromatic amide fibers, aluminum oxide fibers, silicon carbide fibers or mixtures thereof are used.
- Laminated materials have a clearly higher damage tolerance characteristic compared to equivalent monolithic sheets.
- the crack propagation characteristics of fiber-reinforced metal laminates are 10 to 20 times better than those of monolithic sheets.
- the mechanical properties of a metal can be improved by infiltrating the metal into a reinforcing structure, whether spontaneous, pressure-assisted or vacuum-assisted.
- One method is to incorporate the reinforcing particles in a first step in a polymer matrix, then remove the polymer by using a variety of different methods, leaving behind a loosely formed preform scaffold (preform) consisting of the reinforcing particles, which is then infiltrated by a liquid metal.
- preform preform scaffold
- the mechanical properties of the resulting MMC are mostly limited by the degree to which the polymer binder can be removed.
- MMCs manufactured in the above described way rely on a good mechanical interface between the reinforcing particles and the metal matrix since there is no direct interconnection between the reinforcing particles themselves. In most cases the interface has to be prepared in a separate step by functionalizing the surfaces of the reinforcing particles prior to embedding them in the polymer. Functionalization, polymer embedding, and polymer removal are additional manufacturing steps which make this type of MMCs rather expensive, limiting their industrial application. It is therefor desirable to develop a method for making an MMC, wherein these steps are not necessary.
- U.S. Pat. No. 5,020,584 discloses a method of infiltrating of a preform, formed from a mixture of a powdered matrix metal and a powder filler (ceramic), with a molten metal. It is disclosed that when the powdered matrix metal is aluminum and the filler aluminum oxide, the infiltrating atmosphere forms a skin (such as an oxide or nitrogen compound) on the metal that prevents particle separation.
- U.S. Pat. No. 5,020,584 is incorporated by reference in its entirety herein. This is a way to use aluminum oxide or aluminum nitride (depending on the gas used for the infiltration process) as the interface which is naturally formed on the surface of each aluminum powder particle.
- PCT/EP2012/052360 discloses a method to use the aluminum oxide structure of the inner tubular walls of halloysite nanotubes (HNTs) as the interface to a surrounding aluminum matrix creating a so called “spot pinning" effect because of the differences in bonding strengths between the aluminum matrix on the one side, and the end segments and the remaining outer wall areas of the reinforcing HNTs on the other side. This leads to a so called internal "micro torque" effect in the material giving it excellent tensile strength properties.
- HNTs halloysite nanotubes
- US 2003/0084970 A1 describes a titanium alloy having high ductility, fatigue strength, and rigidity, and a method of making the same.
- the specific an objective of the invention was to develop a titanium alloy which is capable of hot forging or hot rolling, and which has a tensile strength not less than 1100 MPa and a Young's modulus not less than 130 GPa, together with high ductility and fatigue strength.
- the Young's modulus of a titanium alloy was enhanced by dispersing particles having a high Young's modulus into the titanium matrix.
- the dispersed particles are titanium carbide or titanium boride particles, which are produced by crystallization and/or precipitation in the matrix.
- Biomorphic materials as a new kind of carbon containing composite materials, are usually fabricated by carbonizing wood or wood like materials impregnated with phenolic resin under vacuum at an elevated temperature of 300 ⁇ 2800°C. Biomorphic materials not only offer the potential of improved material properties of the bulk material but also maintain the micro-fine structure of the natural biological materials, thus transferring structural properties like flexibility to artificial materials. Biomorphic materials are currently used as self-lubricating materials, biomedical materials, heat insulating materials, and for electromagnetic shielding (Griel P 2001 J. Eur. Ceram. Soc. 21 105, Zhang Di, Sun Binghe and Fan Tongxiang 2004 Sci. China E47 470, Odeshi A G, Mucha H and Wielage B 2006 Carbon 44 1994).
- bio-templates bio-preforms
- the present invention uses the so called “spot-pinning" effect of halloysite nanotubes (HNTs) in an aluminum matrix which was disclosed earlier in PCT/EP2012/052360.
- PCT/EP2012/052360 discloses that the ends of a HNT in an aluminum matrix are much stronger mechanically interconnected to the surrounding aluminum matrix than the other areas of the outer hull of the HNT because of the Al2O3 interface present at the open ends of the tubes.
- Figure 1 shows a HNT where the end regions of the tube having a high bonding strength to the surrounding aluminum matrix are marked with circles.
- PCT/EP2012/052360 then discloses the so called "micro-torque" effect acting on individual HNTs which gives the compound material a superior mechanical strength in comparison to the pure matrix material, because the torque, induced by external stress and acting on each individual HNT, is transferred to the aluminum matrix and converted into heat.
- a maximum of tensile strength improvement was disclosed at a loading of about 10 weight percent (w%) of HNTs in the aluminum matrix.
- the present invention relies on a concentration of HNTs in the aluminum matrix which is high enough, so that the areas around the end parts of the HNTs overlap, where the mechanical interface to the surrounding aluminum matrix is strong (Figure 2). If the HNTs are randomly distributed in the aluminum matrix, several HNTs can dock on the same interfacing region under different angles ( Figure 3). In a three dimensional situation this means that an irregular network, or scaffold, of randomly interconnected HNTs can develop in the aluminum matrix ( Figure 4).
- the HNTs (grey bars) can be regarded as elastic beams, interconnecting the areas of strong mechanical attachment (marked as black circular shapes) around the ends of different HNTs.
- the concentration (weight percentage) of the HNTs in the matrix influences the type of scaffold formed in the aluminum matrix. If the concentration is low, relatively simple structures are formed ( Figure 05). However, if the concentration of HNTs is high, complex three dimensional networks are created. ( Figure 06). In any case, the overlapping areas of strong mechanical interfacing represent areas where the compound has a higher strength than in the other areas. The result of a numerical simulation of this effect for a sample containing 60 w% HNTs is shown in Figure 07.
- the voids black elliptical areas
- Figure 9 shows the result of a numerical simulation for a sample containing 45 w% HNTs in an aluminum matrix.
- FIG. 11 shows a micrograph taken from the etched fracture surface of a real aluminium / HNT compound material sample with a concentration of 60 w% HNT in the aluminum matrix and a wide length spectrum of the HNTs (Figure 12).
- the HNT network is clearly visible in Figure 11 and corresponds qualitatively to the corresponding simulation prediction.
- FIG. 12 shows that, if the simulated sample is exposed to a compression stress, the HNTs behave like elastic beams of constant length, interconnected by joints which correspond to the areas of high strength in the matrix. Since aluminum is much softer than the HNTs the aluminum matrix is deformed under the compression stress and slides along the HNTs while the HNTs keep their length and only swivel in the interconnection hinges. The aluminum matrix practically acts as a high viscosity damping medium in which a the scaffold of stiff HNTs, which are interconnected by three dimensional hinges, is embedded.
- step 1) Powder metallurgical mixing of aluminum powder with HNTs.
- the inner tubular space of the HNTs is filled (completely or in part) with aluminum particles. This process was disclosed earlier in PCT/EP2012/052360.
- the filled HNTs are then separated from the residual aluminum powder and ready to be used in the following steps.
- step 2) Stir casting of a blend of liquid aluminum and the aluminum powder filled HNTs prepared in step 1.
- a blender crucible first melts the aluminum alloy prior to blending. Then the HNTs are added via a commercial feeder system. The HNTs are mixed into the liquid aluminum with a mixing impeller, that is submerged into the melt. The blend is kept in the the crucible blender long enough to allow the aluminum particles sitting the inner tubes of the HNTs to melt ( Figure 13, picture source: Advanced Materials & Processes /July 2001).
- step 3 After the blending step, the MMC material is transferred to a separate preheated holding furnace.
- the holding furnace has a built-in low-speed magnetic hydrodynamic (MHD) mixing system, producing a gentle circular agitation that keeps the HNTs from settling out without any mechanical stirrer or any other mechanical means disturbing the liquid aluminum / HNT blend.
- MHD magnetic hydrodynamic
- the temperature of the holding furnace is then slowly lowered while the mixing frequency of the MHD system is reduced simultaneously.
- the cooling rate has to be slow enough to give the HNTs enough time to self arrange and form a scaffold when the areas of higher bonding strength between the aluminum matrix and the HNT ends are interconnecting.
- the Al2O3 brought in on the surface of the powder particles filled into the inner tubes of the HNTs in step 1 now acts as an effective mechanical interface between the aluminum matrix and the Al2O3 like inner wall structure of the HNTs.
- the MHD stirring system is switched off which causes the circular motion of the melt to slowly stop.
- the cooling rate is increased to a high value causing the blend to solidify while the HNT scaffold in the matrix is frozen in.
- the solidified ingot represents then the self stabilized halloysite / aluminum matrix compound as an embodiment of this invention.
- Figure 01 Schematic picture of a halloysite nanotube wherein the areas of strong mechanical bonding with the aluminum matrix are marked with circles.
- Figure 02 Two halloysite nanotubes interlinked in a joint area of strong mechanical bonding with the aluminum matrix.
- Figure 03 Three halloysite nanotubes interlinked in a joint area of strong mechanical bonding with the aluminum matrix under various angles.
- Figure 04 Three dimensional scaffold formed by interlinked halloysite nanotubes in the aluminum matrix.
- Figure 05 Simple scaffold structure at low HNT concentrations in the aluminum matrix.
- Figure 06 Complex scaffold structure at low HNT concentrations in the aluminum matrix.
- Figure 07 Simulated strength structure for a concentration of 60 w% of HNTs in an aluminum matrix.
- Figure 08 Micrograph of the internal structure of a Walnut wood sample.
- Figure 09 Simulated strength structure for a concentration of 45 w% of HNTs in an aluminum matrix.
- Figure 10 Micrograph of the internal structure of a Pine wood sample.
- Figure 11 Micrograph of the etched fracture surface of an aluminium / HNT compound material sample containing 60 w% HNT in the aluminum matrix.
- Figure 12 Length distribution of the halloysite nanotubes as received.
- Figure 13 Schematic of a blender crucible used for mixing the HNTs homogeneously into the liquid aluminum (picture source: Advanced Materials & Processes /July 2001).
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- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Manufacture Of Alloys Or Alloy Compounds (AREA)
Abstract
L'invention concerne l'incorporation d'un réseau mécaniquement relié de nanotubes d'halloysite fixés trou par trou dans une matrice d'aluminium qui crée un matériau de composé ductile ayant un réseau interne super-élastique tridimensionnel de fibres d'halloysite et d'aluminium en tant qu'amortisseur intégré de viscosité élevée. Le matériau composite d'alliage d'Al renforcé par de l'halloysite montre d'excellentes propriétés de résistance spécifique, module spécifique d'élasticité, fatigue, et ductilité.
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2017157835A1 (fr) * | 2016-03-18 | 2017-09-21 | Höganäs Ab (Publ) | Composition de poudre métallique ameliorant l'usinabilité |
Citations (5)
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EP0056288A1 (fr) | 1981-01-09 | 1982-07-21 | Technische Universiteit Delft | Laminé en tôle métallique et des fils liés à ces tôles et ses procédés de fabrication |
EP0312151A1 (fr) | 1987-10-14 | 1989-04-19 | Akzo N.V. | Laminé en couches de métal et de matière synthétique renforcée par des filaments continus |
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EP0573507A1 (fr) | 1991-03-01 | 1993-12-15 | The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern | Lamines en alliage renforce |
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EP0056288A1 (fr) | 1981-01-09 | 1982-07-21 | Technische Universiteit Delft | Laminé en tôle métallique et des fils liés à ces tôles et ses procédés de fabrication |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2017157835A1 (fr) * | 2016-03-18 | 2017-09-21 | Höganäs Ab (Publ) | Composition de poudre métallique ameliorant l'usinabilité |
KR20180123517A (ko) * | 2016-03-18 | 2018-11-16 | 회가내스 아베 (피유비엘) | 용이한 기계가공을 위한 분말 금속 조성물 |
KR102404084B1 (ko) | 2016-03-18 | 2022-05-30 | 회가내스 아베 (피유비엘) | 용이한 기계가공을 위한 분말 금속 조성물 |
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